Owens Corning
During my CO-OP at Owens Corning, I served as a Maintenance Engineering Student in their maintenance department. This experience was truly exceptional, providing me the opportunity to engage in a wide array of projects, including nozzle designs, pump rebuilds, and the creation of electrical diagrams.
Over the course of my four-month term, I had the privilege of collaborating with a highly skilled team of engineers, millwrights, and electricians. Working alongside these professionals not only expanded my technical knowledge but also imparted invaluable lessons that have greatly contributed to my professional growth.
Here, I've highlighted some of the major projects I had the chance to complete during this intensive and rewarding CO-OP term.
Forming Chain Cleaner
The problem; the forming chain is a key conveyor line that carries the treated fiberglass. Due to its constant running and the nature of the fiberglass, it is constantly getting clogged with waterlogged fiberglass particles. Which then decreases the efficiency of the line. The current solution was to have a cleaning company, clean the line monthly with their special power washers. However, this required the entire production line to be shut down for a few hours at a time, increasing downtime. To add, the service was at times unreliable due to the equipment breaking down as well as costly. Thus, a cheaper, more reliable system that would not cause as much downtime was needed. For reference, the picture to the right showcases where the chain was being cleaned.
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The solution; In tackling the issue of our forming chain perpetually clogging with waterlogged fiberglass particles, we brainstormed various design ideas. Concepts ranged from nozzles on tracks to a spinning arm with pencil jets, and even a scaled-down version of the existing cleaning equipment in use. After careful consideration, we opted for a smaller version of the existing equipment for a couple of reasons.
Firstly, cost played a significant role in the decision-making process. The estimate for this design was just a few hundred dollars, making it the most budget-friendly among the proposed solutions. Additionally, there were concerns with nozzle clogging in another system, reinforcing the practicality of a smaller, more maneuverable design.
To bring this concept to life, I collaborated with the cleaning company, took measurements of their current systems, and utilized early CAD designs from a previous student. The finalized design offered three key advantages. It was cost-effective, with the total expenses, including materials and man-hours, staying under $300. Its adaptability was enhanced by designing adjustable axles and cylinder base attachment points, accommodating variations in track width and distance from nozzles to the chain. Lastly, its lightweight construction, around 25-30 pounds, marked a significant improvement, making the equipment 45 pounds lighter than the current setup. This reduction in weight allowed for a single-operator setup, minimizing manpower and downtime – a step towards a more efficient and cost-effective solution for the long term.
The results; The pictures on the right showcase our final product and the day we put it to the test on the chain. Early feedback from the millwrights and engineers made it clear that the 45-degree angle for the steel frame connection wasn't the strongest move. They suggested going with two overlapping 90-degree parts for a more solid setup. Even though we did the entire design in-house and it was a one-piece deal, I initially did not think of the importance of hole tolerances. However, considering how the axles and nozzle heights depend on those holes, especially for the 3/8-inch ones, it's a good call to have them nailed down.
On the test day, our new design did manage to clear some fiberglass particles, but it wasn't on par with the cleaning company's setup. Three main issues popped up. First, the distance from the chain to the nozzle was a problem because of a lip at the entry point. We had to keep the nozzles higher to avoid hitting and damaging the chain, which spread out the water streams and made them less effective. Also, our pressure (2,500 PSI) was weak compared to the cleaning company's industrial-grade setup. Lastly, the fan-shaped nozzle we tested covered more area, but since the chain moves during cleaning, pinpointing streams at a specific area turned out to be more crucial than covering a broad space.
Fiberglass Air Gun
The problem; the Separator Wheel was a grinder for scrap fiberglass, that allowed the plant to recycle almost all of its cuttings and trimming to eliminate waste and stay cost-effective. The issue is that it needs to be routinely cleaned to prevent extremely fine fibers from clogging the grinder. The current practice was for an operator to use an air wand, lock out the system, and then clean the grinder with said air gun. However, this would lead to downtime as well as there always being a safety consideration due to a piece of equipment needing to be locked out. Thus, there was a need for a new design that would clean the grinder without causing the machine to be locked out while still maintaining the provincial safety standards.
The solution; I remember in my first year of university I had a professor mention to us that the main object of a drawing is to get a message across and that as engineers we need to find what the best medium is to get that message of idea conveyed. I really didn't understand what that meant at the time as to me, creating a 3D model of your design always seemed as the best option. However, the air gun design proved me otherwise. As I began to craft a 3D of what I thought would be the best idea for an air gun on a track however when I went to explain it to the millwright that would be building the project it became quite clear how ineffective the message was. This was because of the size of the design, and the way I thought it should be built. As I was trying to depict a 6ft long track as well as a 6inch trolley which the air gun would use. As such, I recognized that it would be much easier to sit down with the millwright and sketch hand what he and I think would be the best approach to the given problem. This resulted in the hand sketch below.
The solution cont'd/results; This design was chosen as it allowed the operator to clean the grinder behind the safety guards. This was possible due to the track system in which the air gun rested. This in turn allowed for the equipment to still be able to run while being cleaned. This meant that not locking out of the equipment was required, increased safety as employees were behind the guards as well as an optimal nozzle height as the gun height was fixed to be as close as possible without damaging the grinder. Moreover, since the worker didn't not have to hold the air gunt the risk of a repeated strain injury was also limited. To add the back of the track as well as the very front use a bolt through the strut to prevent the trolleys from going completely out of the track. This also allows for maintenance as if the nozzle becomes clogged then the air gun can be removed by unscrewing the bolt in the strut and sliding the trolly out. Allowing for easy maintenance. The final design in action is shown below!
Takeaway; this project taught me a lot about what the end goal of a drawing or presentation is and how to determine what the best medium is for the job at hand. Moreover, I also got to learn a lot about operator safety and how to ensure designs are implemented in a way that minimizes risk while still being efficient. Which in this case was being able to clean without having to lockout the machine. Alll in all this experience was one that I had a great time designing and learning from!
Miscellaneous Projects
Here are some other notable projects that I was able to complete during my time with Owens Coring but weren't big enough or weren't able to add much information/photos due to confidentiality.
Piping Isometrics; Taking on the task of designing the pipe layout for the new equipment requiring a potable water supply was no small feat. The pipe fitters needed a rough estimate for materials and man-hours to provide a quote, and that's where I stepped in. Crafting the layout involved figuring out the main water header and creating a piping isometric that ensured an efficient, cost-effective, and practical supply and return. The challenge lay in weaving these lines of pipe through the existing labyrinth of other pipes and equipment in the plant layout.
Once the piping isometrics were done, I walked the layout with the pipe fitters. This hands-on experience allowed me to grasp how they quote a project of this magnitude and understand the real-world considerations needed to build my design. After some back and forth, discussing and fine-tuning to determine the most optimal setup, we managed to achieve a piping layout that satisfied all parties involved. It was a lesson in translating design into practical implementation and finding that sweet spot where efficiency, cost-effectiveness, and practicality intersect.
Five-Figure Pump Project; Dealing with the plant's need for pump upgrades in its potable water system involved quite a bit of reaching out. I had to connect with suppliers and contractors to meticulously put together a comprehensive pump pricing outline. This detailed document covered various upgrade options for the pumps, including lead times for completing different segments of the upgrades. It was a task that required careful coordination and communication, but it felt like a tangible contribution to enhancing the plant's essential water infrastructure.
Transfer Vessel Thickness; Taking on the project with the 20-plus holding vessels was a real test of how willing I was to get my hands dirty. These vessels, holding various materials, faced interior wear and tear, prompting the need for an ultrasonic sensor to measure vessel thickness. The challenge? The sensor required grease for lubrication, and with the abundance of fibers and dust in these vessels, I found myself immersed in a messy situation. Crawling through those vessels meant ending up covered in a blend of grease, fibers, and what felt like tarbird – and I loved every second of it. It was a refreshing break from the heavy CAD work, allowing me to get hands-on, even if those hands were deep in grease!
PLC Drawings; Dealing with the variety of electrical drawings at the plant became an unexpectedly intricate task. Initially, I thought updating them was a simple and somewhat tedious job. However, as I delved into it, I realized that over the past 30 years, each engineer and electrician had left their mark on the drawings, resulting in a mosaic of different styles. While this might be desired for fine art, it posed challenges in a manufacturing plant where interpreting drawings is crucial.
To bring order to this artistic chaos, I took on the task of creating a standard design and template for all common PLC racks. The idea was that when editing or creating a new drawing, the standardized templates would ensure consistency across all the plant's drawings. Initially, I treated this task as a way to switch off and mindlessly input information. However, a wake-up call came when an E-STOP present in reality wasn't shown on the drawing, causing an unexpected 30-minute downtime.
This incident made me realize the importance of finer details. Consequently, I adopted a meticulous approach, printing out the final drawings and going over each aspect with a red pen to ensure nothing was overlooked before sending them out. It turned out to be more than just a task to occupy my mind—it became a critical aspect of ensuring accuracy and minimizing potential issues on the plant floor.